Stackable shipping and display box

ABSTRACT

An elongate, rectangular box ( 12, 14, 40, 60, 70, 90, 100 ) and method for packaging containers (C), wherein the box can be cross-stacked for stable stacking of the boxes, and optimizes utilization of pallet space. Containers (C) are placed in the box in nested, offset relationship in a parallelogram shaped arrangement, and in one embodiment interior corner panels ( 20, 21 ) extend angularly across two diagonally opposite corners of the box, defining an interior box shape closely conforming to the parallelogram-shaped arrangement of the containers. The corner panels may be cut from the side walls ( 18, 19 ) and folded inwardly and secured at a free edge ( 28 ) to an adjacent end wall ( 16, 17 ), defining openings ( 22, 23 ) in the side wall through which the containers are visible. Side wall segments ( 24, 25, 26 ) at the bottom and sides of the opening, in cooperation with the corner panels, retain the containers in place in the box. The box is especially suited for packaging four one-gallon containers.

TECHNICAL FIELD

This invention relates to packaging, and more particularly to astackable shipping and display box.

BACKGROUND ART

Many products are shipped in cartons or boxes that enable the product tobe displayed in the shipping box at the point of sale. These types ofboxes are particularly suitable for products sold in club stores, wheremany products, e.g., juices, typically are packaged in one-galloncontainers. Conventional boxes for handling one-gallon containersusually comprise full depth closed RSC's, although partial depth boxesor trays are sometimes used. A divider that extends between thecontainers normally is used in the partial depth trays to provideadequate strength. Further, conventional boxes for holding one-galloncontainers are commonly designed for holding six containers, althoughsome packages, such as those shown in FIGS. 1 and 2, are designed forholding four containers, primarily due to weight concerns. Theseconventional boxes are square in plan view, with the one-galloncontainers orthogonally oriented in side-by-side relationship to oneanother.

To facilitate handling, it is common practice to stack several layers offilled boxes on a pallet, and sometimes to stack two or more palletshigh. Conventional square boxes are often column stacked, and typicallyrequire internal or external support to eliminate or reduce load on thebottles. Column stacking of the boxes is inherently unstable, and layersheets, or slip sheets, may be employed between adjacent layers of boxesto improve the stability of the stacked boxes.

Moreover, the pallets used typically have dimensions of 48×40 inches,and the square boxes do not utilize the pallet space well, i.e., aplurality of the boxes placed in a layer either do not occupy the entirepallet space, or they overhang the pallet, depending upon how the boxesare oriented and how many are placed in a layer on the pallet.Conventional square boxes do not permit any arrangement of the boxes ona pallet that will result in the footprint of the area occupied by theboxes being substantially equal to the shape and area of the pallet.When conventional square boxes holding four one-gallon containers areplaced on a conventional 48×40 inch pallet, often only nine boxes, orthirty-six one-gallon containers, can be accommodated in each layer ofboxes without overhanging the edges of the pallet, depending upon thebottle diameter and/or footprint.

Accordingly, there is need for a box for shipping and displayingproduct, wherein the box, when filled with containers of product, has amaximum desired weight and is configured to enable stable stacking offilled boxes, pallet space is optimally utilized, and no load isproduced on the product containers, all without requiring the use ofseparate layer sheets, or separate internal or external reinforcements.

DISCLOSURE OF THE INVENTION

The present invention comprises a box for shipping and displayingproduct, wherein the box is configured so that filled boxes can bestacked in stable, interlocked relationship, pallet space is optimallyutilized, and the product containers are not subjected to load whenfilled boxes are stacked on top of one another.

To accomplish the foregoing, the box of the invention is rectangular,i.e., has a greater length than width, and containers of product areplaced in the box in diagonally offset side-by-side relationship to oneanother. The diagonally offset placement of the containers results ininterior spaces at two diagonally opposite corners of the box, andangled corner panels extend into these spaces to contact the containersto help retain them in the box and to provide stacking support andprevent vertical loads on the containers.

The rectangular shape of the boxes enables boxes in adjacent layers tobe cross-stacked and interlocked for stable stacking. Boxesincorporating the invention can be stably stacked two or more palletshigh and without imposing a vertical load on the containers.

Although the boxes could be configured to hold different numbers andsizes of containers and still incorporate the features of the invention,in the particular embodiments illustrated and described herein they aresized to hold four one-gallon containers. These boxes can be placed on aconventional 48×40 inch pallet so that the footprint of the areaoccupied by a layer of boxes is substantially the same as the area ofthe pallet surface. With the invention, eleven boxes holding forty-fourcontainers can be placed in a layer on a 48×40 inch pallet, although itshould be understood that these numbers can vary, depending upon thebottle diameter and footprint.

Additionally, empty containers, e.g., bottles, can be inverted andplaced upside down in the box by the bottle manufacturer for shipment toa facility for filling the bottles. The shape of the box, including theangled corner panels, securely holds the inverted empty bottles in placeeven when some of the side walls have a reduced height to defineopenings through which the bottles are visible.

Further, the box of the invention, including the angled corner panels,can be made from a single unitary blank of corrugated board, and whenloaded with four one-gallon containers of juice, for example, has a caseweight less than 40 pounds. In an alternate embodiment, the angledcorner panels can be formed from separate pieces inserted into the box.

The box of the invention is equally suitable for use with containershaving a round cross-section or a non-round cross section, e.g., square.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing, as well as other objects and advantages of the invention,will become apparent from the following detailed description taken inconjunction with the accompanying drawings, wherein like referencecharacters designate like parts throughout the several views, andwherein:

FIG. 1 is a top perspective view of conventional partial depth squareboxes or trays filled with four containers placed side-by-side inorthogonal relationship relative to one another and column-stacked on apallet.

FIG. 2 is a top perspective view of a single prior art boxconventionally filled with four containers disposed in side-by-sideorthogonal relationship to one another, and showing an H-shaped dividerin dot-and-dash lines.

FIG. 3 is a top plan view depicting how conventional square boxesdesigned for holding four one-gallon containers occupy the space on aconventional 48×40 inch pallet.

FIG. 4 is a top perspective view of rectangular boxes according to theinvention filled with containers placed in offset side-by-siderelationship relative to one another and cross-stacked on a pallet ininterlocking relationship.

FIG. 5 is a top perspective view of a single rectangular box accordingto the invention filled with four containers disposed in side-by-sideoffset relationship to one another.

FIG. 6 is a top plan view depicting how rectangular boxes according tothe invention and designed for holding four one-gallon containers occupythe space on a conventional 48×40 inch pallet.

FIG. 7 is a top plan view depicting how the rectangular boxes of theinvention might be alternately arranged on a pallet.

FIG. 8 is a top perspective view of a first embodiment of a boxaccording to the invention, showing four containers of roundcross-section disposed therein in offset relationship to one another,and wherein the box is made from a single unitary blank, with two sidewalls of substantially reduced height.

FIG. 9 is a top plan view of a blank for making the box of FIG. 8.

FIG. 10 is a top plan view of the box of FIG. 8.

FIG. 11 is a top perspective view of the box of FIG. 8, showing fourinverted containers placed therein in upside-down, offset relationship.

FIG. 12 is a top perspective view of a second embodiment of the box ofthe invention, wherein the box is constructed substantially the same asthe box of FIG. 8, except that the side walls are only partially reducedin height.

FIG. 13 is a top plan view of a blank for making the box of FIG. 12.

FIG. 14 is a top perspective view of a third embodiment of the box ofthe invention, wherein the box is constructed substantially the same asthe box of FIG. 8, except that the side walls are not reduced in height.

FIG. 15 is a top plan view of a blank for making the box of FIG. 14.

FIG. 16 is a top perspective view of a fourth embodiment of the box ofthe invention, wherein the box is made from one blank, the angled cornerpieces comprise inserts made from additional blanks, and wherein theside walls and end walls are all of reduced height.

FIG. 17 is a top plan view of a blank for making the box of FIG. 16.

FIG. 18 is a top plan view of a blank for making the inserts used in thebox of FIG. 16.

FIG. 19 is a top plan view of the box of FIG. 8, with containers havinga square cross-section therein.

FIG. 20 is a top perspective view of a fifth embodiment of the box ofthe invention, wherein the reduced height side walls are defined bycut-outs in full height panels forming those side walls.

FIG. 21 is a top plan view of a blank for making the box of FIG. 20.

FIG. 22 is a top perspective view of an alternate embodiment of a boxincorporating the invention, wherein one end wall is cut away to producean opening through which the containers are visible.

FIG. 23 is a top perspective view showing a plurality of the boxes ofFIG. 22 placed on a pallet, and showing how the footprint of the areaoccupied by the boxes is substantially the same as the area of thepallet surface.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

A conventional box of square shape designed for holding four one-galloncontainers C is shown at 10 in FIGS. 1-3. In accordance withconventional practice, the containers are placed in the box inorthogonally disposed side-by-side relationship to one another, and anH-shaped divider 11, shown in dot-and-dash lines, is placed in the boxbetween the containers. Boxes filled with containers are typicallystacked in layers on a pallet P, and as depicted in FIGS. 1 and 2, theboxes are stacked on top of one another in columnar relationship. Thisarrangement is unstable, and layer sheets (not shown) are commonlyplaced between adjacent layers. Moreover, only nine boxes may be placedin a layer without producing pallet overhang, but this results in asubstantial area of the pallet not being used.

The invention solves this problem, as depicted in FIGS. 4-7, by makingthe boxes 12 rectangular in shape, with a greater length dimension Lthan width dimension W, and placing the containers C in the box so thatthey are in offset or staggered relationship, as seen best in FIGS. 5and 6. With this arrangement, the boxes may be cross-stacked ininterlocking relationship to produce a stable stack without requiringthe use of layer sheets. Moreover, the boxes may be arranged on thepallet P so that the footprint or area occupied by the boxes issubstantially equal to the surface area of the pallet, thus enablingoptimum pallet utilization.

The boxes may be arranged in different ways to achieve interlocking whenstacked and to maximize use of the pallet surface, as depicted forexample in FIGS. 6 and 7.

A second embodiment of a box according to the invention is shown at 14in FIGS. 8-11 and 19. The box 14 has a bottom wall 15, opposite endwalls 16 and 17, opposite side walls 18 and 19, and angled interiorcorner panels 20 and 21 extending across the interior of the box from arespective side wall to an adjoining end wall at each of two diagonallyopposite corners of the box, defining a generally parallelogram-shapedbox interior, as seen best in FIG. 10.

Large openings 22 and 23 are formed in the side walls, extending fromthe top of the wall to an upstanding, narrow, bottom side wall segment24 at the bottom of the opening, and offset slightly toward respectiveopposite ends of the box, defining a narrow first side wall end segment25 at one end of the side wall, and a relatively wider second side wallend segment 26 at the other end of the side wall. The angled interiorcorner panels are foldably joined at one edge 27 to the respectivesecond side wall end segments at the edge of the respective openings 22and 23, and are affixed to the adjacent end wall by a glue flap 28 onthe opposite free edge of the corner panel.

When four one-gallon containers C are placed in the box, they areoriented in nested, offset or staggered relationship as depicted inFIGS. 5, 6 and 8. The containers, and thus labels or graphics on thecontainers, are visible through the large openings 22 and 23, and thecontainers are retained in the box by the upstanding narrow bottom sidewall segment 24, the angled interior corner panels 20 and 21, and thenarrow first side wall end segment 25.

The interior corner panels 20 and 2 1 and adjacent side and end wallportions define triangular reinforcing strictures at two diagonallyopposite corners of the box, lending stacking strength to the box andenabling boxes filled with containers to be stacked two or more palletshigh without imposing load on the containers.

A blank B, for forming the box of FIGS. 8 and 10 is shown in FIG. 9, andcomprises a single unitary piece of corrugated board that is die-cut andscored to form an elongate, rectangular center panel 30 that forms thebottom wall 15 in the erected box. First side wall panels 31 and 32 arefoldably joined to opposite side edges of the bottom-forming panel 30,and define the bottom side wall segments 24 in the erected box.End-wall-forming panels 33 and 34 are foldably joined to opposite endsof the bottom-forming panel 30, and a second side wall panel 35 isfoldably joined along one edge of each panel 33 and 34 to form thenarrow first side wall segments 25 in the erected box. Relatively widerthird side wall panels 36 and 37 are foldably joined along one edge tothe opposite side edges of the panels 33 and 34, and form the second,wider side wall segments 26 in the erected box. Corner panel-formingpanels 38 and 39 of greater width than the panels 36 and 37 but narrowerthan panels 30-34 are foldably joined along one edge to the panels 36and 37 and form the angled interior corner panels in the erected box.Narrow flaps 40 and 41 are foldably joined to the opposite edges ofpanels 38 and 39 and form the glue flaps 28. In the erected box, theglue flaps 28 are adhesively secured to an interior surface of theadjacent end wall, and the flaps 31 and 32 are folded upwardly and gluedto an outer surface of the respective side end wall segments 25 and 26.

It will be noted that a continuous score 42 extends along the length ofthe blank at opposite sides of the bottom-wall-forming panel 30 and theend-wall-forming panels 33 and 34, and in the particular example shown,short cuts 43 are spaced along these scores. Further, in the particularexample shown, the scores 44 separating the panels 36 and 38 and thepanels 37 and 39, and the scores 45 separating the panels 38 and 40 andthe panels 39 and 41 comprise lines of perforations 46. It should beunderstood, however, that the cuts and perforations need not be employedand the scores could comprise creased areas.

As indicated in FIG. 1, the containers C may be inverted and placedupside down in the box 14, where they are retained by the angled cornerpanels 20 and 21, the bottom side wall segment 24 and the narrow sidewall segment 25. This feature enables the container manufacturer toplace empty containers in the box for shipment to a facility where thecontainers are to be filled.

A third embodiment of the box of the invention is shown at 50 in FIG.12. This embodiment is substantially the same as the first embodiment 14described above, except the bottom wall segments 51 and 52 aresubstantially wider, resulting in effectively higher side walls and asmaller-opening through the side walls, and the glue flaps 53 thatattach the free edge of the angled interior corner panels 54 and 55 tothe adjacent end walls are wider, extending all the way into theopposite corner of the box.

A blank B₂ for forming the box of FIG. 12 is shown in FIG. 13, and isessentially the same as the blank B₁ described above, except for thewider panels 56 forming the bottom side wall segments 51 and 52, and thewider panels 57 forming the corner panel glue flaps 53.

A fourth embodiment of the box of the invention is shown at 60 in FIG.14, and is essentially the same as the first embodiment 14 describedabove, except that the side walls 61 and 62 are full height, with noopening or cut-out in them.

A blank B₃ for forming the box of FIG. 14 is shown in FIG. 15, and isessentially the same as the blank B₁ described above, except for thewidth of side wall panels 61 and 62, which have the same width as theheight of the end walls.

A fifth embodiment of the box of the invention is shown at 70 in FIG.16. In this embodiment, separate inserts 71 and 72 of triangularcross-section are inserted into two diagonally opposite corners of apartial depth rectangular box or tray 73 similar to the box 12 shown inFIGS. 4-6. The box 73, taken alone, is of substantially conventionalconstruction and can be used for many purposes. It has side and endwalls 74 and 75 of equal height, but only about one-half the height ofthe containers C placed in the box. In accordance with the presentinvention, the inserts 71 and 72 project above the height of the sideand end walls and slightly above the height of the containers.

A blank B₄ for forming the box 73 is shown in FIG. 17, and comprisesfour rectangular panels 76, 77, 78 and 79 foldably joined together alongspaced transverse score lines 80. A glue tab 81 is foldably joined to apanel 79 at one end of the blank for adhesive attachment to the panel 76at the opposite end of the blank when the box is erected. Bottom formingflaps 82, 83, 84 and 85 are foldably connected along one edge of therespective side-wall-forming panels 76, 77, 78 and 79.

A blank B₅ for forming the triangular corner inserts 71 and 72 is shownin FIG. 18 and comprises first, second and third panels 86, 87 and 88joined along scores 89.

In FIG. 19 a plurality of containers C of square cross-section are shownplaced in the box 14 of FIGS. 8-11. This capability exists for allembodiments of the invention. This figure also clearly shows how thecontainers are retained in place in the box in spite of the largeopenings through the side walls.

A sixth embodiment of the box of the invention is shown at 90 in FIG.20. This embodiment is similar to the embodiment of FIG. 8, except thepanels 91 and 92 foldably joined to opposite side edges of thebottom-forming panel 30 have a width to extend the full height of thebox, and shaped cut-outs 93 are formed in them to provide the openingsthrough which the containers are visible. This arrangement also producesa double thickness side wall 94 in the area between the respectiveangled interior corner panels 20 and 21 and the adjacent end walls.

A blank B₆ for forming the box 90 is shown in FIG. 21. This blank is thesame as the blank B₁ shown in FIG. 9, except for the panels 91 and 92and the cut-outs 93 in these panels.

A seventh embodiment 100 is shown in FIGS. 22 and 23, and is similar tothe embodiment shown in FIGS. 4 and 5, except in this embodiment theside walls 101 and end walls 102 have a height greater than the heightof containers C placed in the box, and a cut-out 103 is formed in oneend wall.

While particular embodiments of the invention have been illustrated anddescribed in detail herein, it should be understood that various changesand modifications may be made to the invention without departing fromthe spirit and intent of the invention as defined by the scope of theappended claims.

1. A package for shipping and storing containers of product, saidpackage comprising a rectangularly shaped box having a greater lengththan width and having a bottom wall, opposite end walls, and oppositeside walls disposed orthogonally to the end walls and defining anelongate interior space in which containers of product are placed innested, offset relationship to one another in a generallyparallelogram-shaped arrangement.
 2. A package as claimed in claim 1,wherein: angled interior corner panels extend diagonally across twodiagonally opposite interior corners the box, defining a generallyparallelogram-shaped box interior; and said parallelogram-shapedarrangement of the nested and offset containers therein conforms to theinterior shape of the box, whereby the containers are closelyconstrained against movement in the box.
 3. A package as claimed inclaim 2, wherein: at least one said side wall has an opening thereinthrough which the containers are visible.
 4. A package as claimed inclaim 3, wherein: both said side walls have an opening therein, definingat least portions of said side walls of reduced height; and saidinterior corner panels are cut from said side walls, defining saidopenings, and then folded inwardly toward an adjacent end wall to formsaid angled interior corner panels.
 5. A shipping and display box forcontainers of product, comprising: a bottom wall, opposite end walls,and opposite side walls disposed orthogonally to the end walls to definean elongate rectangularly shaped box having four corners; and angledinterior corner panels extending across two diagonally opposite cornersof the box, defining a generally parallelogram-shaped interior space inthe box, whereby a number of containers can be placed in the box innested, offset relationship to one another in a parallelogram-shapedarrangement that conforms closely to the interior shape of the box, saidelongate rectangular shape of the box enabling the boxes to becross-stacked and interlocked with one another to produce a stable stackof the boxes.
 6. A box as claimed in claim 5, wherein: the side and endwalls and interior corner panels have a height that is at least as greatas the height of containers placed in the box, whereby boxes filled withcontainers may be stacked on top of one another without imposing a loadon the containers, said interior corner panels serving to impartstacking strength to the box as well as defining saidparallelogram-shaped interior space that conforms closely to theparallelogram-shaped arrangement of containers placed therein.
 7. A boxas claimed in claim 6, wherein: at least a portion of at least one saidside wall is of reduced height, defining an opening through said atleast one side wall, whereby containers placed in the box are visiblethrough the opening.
 8. A box as claimed in claim 7, wherein: at leastportions of both side walls are of reduced height, defining openingsthrough which containers placed in the box are visible, and saidinterior corner panels are cut from said side walls to form saidopenings, said corner panels having one edge foldably connected to arespective side wall, and an opposite free edge, said corner panelsbeing folded back from a respective side wall and attached at their freeedge to an adjacent end wall.
 9. A box as claimed in claim 8, wherein:said box is configured to closely conform to and hold four one-galloncontainers disposed in said nested, offset relationship
 10. A box asclaimed in claim 5, wherein: said bottom wall, side walls, end walls,and interior corner panels are formed from a single unitary blank ofcorrugated board.
 11. A box as claimed in claim 5, wherein: said box,including said bottom wall, side walls and end walls, is formed from afirst blank of corrugated board, and said interior corner panels areeach formed from a respective second blank of corrugated board.
 12. Abox as claimed in claim 11, wherein: the interior corner panels comprisethree panels folded and secured together to have a triangularcross-section, and the corner panels have a height that is greater thanthe height of the box side and end walls.
 13. A blank for forming anelongate, rectangular box having a bottom wall, opposite end walls,opposite side walls, and angled interior corner panels in two diagonallyopposite corners, comprising: an elongate, rectangular center panel thatforms said bottom wall in an erected box; opposite end panels foldablyconnected along a first edge to opposite ends of the center panel forforming said end walls in an erected box; a first side wall panelfoldably connected to each of the opposite side edges of the centerpanel; a second side wall panel foldably connected to a second edge,adjacent and perpendicular to the first edge, of each of the end panels;a third side wall panel foldably connected along a first edge thereof toa third edge, opposite the second edge, of each of the end panels; and acorner panel-forming panel foldably connected along one edge to a secondedge, opposite said first edge, of each of the third side wall panels,said corner panel-forming panel having an opposite free edge.
 14. Ablank as claimed in claim 13, wherein: said first and second side wallpanels are narrow, said third side wall panels are wider than said firstand second side wall panels, and said corner panel-forming panels arewider than said third side wall panels.
 15. A blank as claimed in claim13, wherein: said first side wall panels are wider than said second andthird side wall panels, and in an erected box extend approximatelyone-half the height of the box.
 16. A blank as claimed in claim 13,wherein: said first side wall panels are wider than said second andthird side wall panels, and in an erected box extend the full height ofthe box.
 17. A blank as claimed in claim 16, wherein: the edge of eachsaid first side wall panel opposite its folded connection with thecenter panel has a cut-out to define an opening extending over asubstantial portion of the side wall in an erected box.
 18. A blank asclaimed in claim 14, wherein: a glue flap is foldably connected to thefree edge of said corner panel-forming panel to secure the free edge toan adjacent end wall in an erected box.
 19. A method of packagingcontainers in boxes to optimize utilization of pallet space on whichsaid boxes are stacked, and to enable the boxes to be cross-stacked andinterlocked with one another to produce a stable stack, comprising thesteps of: providing a box having an elongate rectangular shape with sidewalls and end walls disposed orthogonally to one another; and placingcontainers in the boxes in nested, offset relationship to one another ina substantially parallelogram-shaped arrangement.
 20. A method asclaimed in claim 19, wherein: the containers are one-gallon containers,and four of the containers are placed in the box.